Material handling for the insulating glass industry

ABSTRACT

Methods and apparatus for handling material for the insulating glass industry are disclosed. One method of handling material for the insulating glass industry in accordance with the present invention includes the step of arranging a plurality of bars into a plurality of stacks with adjacent stacks defining spaces dimensioned to receive a bar engaging member. The stacks of bars may then be transported to a desired destination. A bar engaging member may be inserted into a space defined by the stacks, and one or more bars may be grasped using the bar engaging member. A container for handling material for the insulating glass industry is also disclosed. The container may advantageously include a plurality of prearranged bar locating members configured to hold a predetermined type of bar stock.

RELATED APPLICATIONS

This application is related to and claims priority to U.S. patentapplication Ser. No. 60/262,807 by Trpkovski filed on Jan. 19, 2001 andthe entire disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to methods and apparatus forhandling material for the insulating glass industry. More particularly,the present invention relates to methods and apparatus for handlingelongate barstock that is useful for forming components such as, forexample, spacer frames and muntin bar lattices.

BACKGROUND OF THE INVENTION

Today, insulating glass units have achieved widespread use as buildingcomponents. In order to produce insulating glass units inexpensively andin high volume, modern manufacturing of insulating glass units is oftenmechanized and/or automated. Various materials may be used tomanufacture insulating glass units, including sheets of glass, spacerframes, and various sealants. Insulating glass units may also includemuntin bars. Muntin bars may be used for both functional and decorativepurposes with glass windows or doors. The muntin bars are particularlyuseful when they retain their geometric configuration and do notseparate, as well as when they are able to remain in a flat matingsurface relation with the glass.

SUMMARY OF THE INVENTION

The present invention relates generally to methods and apparatus forhandling material for the insulating glass industry. More particularly,the present invention relates to methods and apparatus for handlingelongate barstock that is useful for forming components such as, forexample, spacer frames and muntin bar lattices. One method of handlingmaterial for the insulating glass industry in accordance with thepresent invention includes the step of arranging a plurality of barsinto a plurality of stacks with adjacent stacks defining spacesdimensioned to receive a bar engaging member. The stacks of bars maythen be transported to a desired destination. A bar engaging member maybe inserted into a space defined by the stacks, and one or more bars maybe grasped using the bar engaging member. In some implementations of theinvention, the step of grasping one or more bars using the first barengaging member includes the steps of inserting a second bar engagingmember into a second space defined by the stacks and trapping one ormore bars between the bar engaging member and the second bar engagingmember.

A container for handling material for the insulating glass industry isalso disclosed. In some implementations, the container includes acontainer frame and a plurality of combs selectively fixed to the frame.In one aspect of the present invention, each comb includes a pluralityof tines that are spaced to define a plurality of channels dimensionedto accept bars having a predetermined width. In another aspect of thepresent invention, the tines are dimensioned to create spaces betweenadjacent channels, with each space being dimensioned to receive a barengaging member. In some implementations, each tine comprises a shaftand a sleeve disposed over the shaft. The sleeve may advantageouslycomprise a no-mar material.

In some implementations, the present invention includes a containerhaving a frame and a plurality of combs that are selectively fixed tothe frame by a coupling mechanism. In some implementations, the couplingmechanism comprises a plunger fixed to the frame of the container and adetent defined by a base of the comb. The detent may be advantageouslydimensioned to accept at least a portion of the plunger. The plunger maycomprise, for example, a ball and a spring arranged to bias the balltoward the detent.

In certain advantageous implementations, the present invention utilizesa container including a first forklift interface and a second forkliftinterface. In some implantations, each forklift interface comprises afirst receptacle and a second receptacle. Each receptacle may comprise,for example, a lumen defined by a tube. In some advantageousimplementations, each forklift interface comprises a first tubepositioned on a first side of a centroid of the container and a secondtube disposed on a second side of the centroid of the container. Whenthis is the case, the first tube and the second tube may beadvantageously positioned substantially equidistantly from the centroidof the container.

A method of handling a first type of bars having a first dimension and asecond type of bars having a second dimension is also disclosed. In someimplementations, this method includes the step of providing a containerincluding a frame and a first set of combs selectively fixed to theframe. Each comb in the first set of combs preferably has a plurality oftines spaced to accept bars having the first dimension. The first set ofcombs may be removed from the container and a second set of combs may beselectively fixed to the frame of the container. In certainimplementations, each comb in the second set of combs advantageously hasa plurality of tines spaced to accept bars having the second dimension.

Another method in accordance with the present invention may include thefollowing steps:

1) Providing a container having a plurality of prearranged muntin barretaining channels configured to hold a predetermined type of bars.

2) Placing a plurality of bars in the retaining channels of thecontainer.

3) Placing a plurality of containers in a transportation vehicle. Insome applications, the containers may be stacked in a semi trailer.

4) Removing the containers from the transportation vehicle.

5) Delivering at least one container to an arrival bay arranged toreceive a container.

6) Sequentially removing bars from the container one at a time.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustrating a method of handling material forthe insulating glass industry.

FIG. 2 is a perspective view of a container in accordance with thepresent invention.

FIG. 3 is a perspective view of an assembly including a vehicle and aplurality of containers that are disposed within the walls of vehicle.

FIG. 4 is a plan view of an assembly including a semitrailer and aplurality of containers located within a plurality of walls ofsemitrailer.

FIG. 5 is a perspective view of a frame assembly in accordance with anexemplary embodiment of the present invention.

FIG. 6 is an exploded perspective view of a portion of frame assembly ofFIG. 5.

FIGS. 7 through 10 are cross sectional plan views of containers inaccordance with the present invention.

FIG. 11 is a perspective view of a system for automatically selectingand retrieving desired material from an appropriate container.

FIG. 12 is an additional perspective view a system of FIG. 11.

FIG. 13 is a cross sectional view of a container assembly in accordancewith the present invention.

FIG. 14 is an additional cross sectional view of the container assemblyof FIG. 13.

DETAILED DESCRIPTION

The following detailed description should be read with reference to thedrawings, in which like elements in different drawings are numberedidentically. The drawings, which are not necessarily to scale, depictselected embodiments and are not intended to limit the scope of theinvention. Examples of constructions, materials, dimensions, andmanufacturing processes are provided for selected elements. All otherelements employ that which is known to those of skill in the field ofthe invention. Those skilled in the art will recognize that many of theexamples provided have suitable alternatives that can be utilized.

FIG. 1 is a flow chart 104 illustrating a method of handling materialfor the insulating glass industry. The material being handled maycomprise, for example, bar stock useful in the insulating glassindustry. Various types of bar stock may be used without deviating fromthe spirit and scope of the present invention. For example, bar stocksuitable for forming spacer frames useful in the insulating glassindustry may be used. By way of a second example, bar stock suitable forforming muntin bar lattices may also be used.

Bar stock used in the insulating glass industry often comprises thinsheet metal (e.g., 4.5 mil stainless steel, 6.0 mil aluminum, and thelike). This thin sheet metal can be easily damaged during handling. Forexample, the bar stock may be scratched, bent and/or dented. Some typesof bar stock may include a finish such as, for example, paint. Thisfinish may be particularly susceptible to scratching.

Block 106A of flow chart 104 comprises the step of providing acontainer. The container may be provided, for example, proximate asource of bar stock. This source of bar stock may be, for example, afactory where bar stock is fabricated. In a preferred method inaccordance with the present invention, the container includes aplurality of prearranged bar locating members configured to hold apredetermined type of bar stock. In some methods in accordance with thepresent, the container is provided at a location where bar stock isbeing fabricated and the bar stock is placed in the container soon afterbeing fabricated. Placing the bar stock in the contained soon after itis fabricated reduces the likelihood that the bar stock will be damaged.

In one exemplary embodiment, the bar locating members comprise tineswhich include a no-mar sleeve. The no-mar sleeve may reduce thelikelihood that the outer surface of the bar stock is scratched duringhandling.

Block 106B of flow chart 104 comprises the step of loading thecontainer. The step of loading the container may involve placing aplurality of bars between the bar locating members of the container.This step may also involve arranging a plurality of bars into aplurality of stacks with adjacent stacks defining spaces dimensioned toreceive a bar engaging member.

Block 106C of flow chart 104 comprises the step of transporting thecontainer. The step of transporting the container may involve placing aplurality of containers in a transportation vehicle. In someapplications, the containers may be arranged in an interlocking fashionin the vehicle. The step of transporting the container may also involveremoving the plurality of containers from the transportation vehicle.The step of transporting the container may also involve delivering atleast one container to an arrival bay arranged to receive the container.The container may be delivered to the arrival bay using a vehicle, forexample, a fork lift.

Block 106D of flow chart 104 comprises the step of inserting a barengaging member into a space defined by adjacent stacks of bar stock.Various bar engaging members may be utilized without deviating from thespirit and scope of the present invention. Bar engaging members suitablefor some applications may comprise, for example, grippers, pinchers,fingers, and vacuum cups.

Block 106E of flow chart 104 comprises the step of removing bar stockfrom the container. In some methods in accordance with the presentinvention, bar stock is removed one piece at a time. In other methods inaccordance with the present invention, a plurality of pieces of barstock are grasped and removed from the container.

Block 106F comprises the step of returning the container. The containermay be returned, for example, to the bar stock source. At the bar stocksource, the container may by reloaded by placing a plurality of barsbetween the bar locating members of the container.

FIG. 2 is a perspective view of a container 100 in accordance with thepresent invention. Container 100 of FIG. 2 includes a plurality ofpre-arranged bar locating members 108 dimensioned and spaced for holdingand dispensing a desired type of bar stock. Container 100 of FIG. 2 alsoincludes a first forklift interface 120A and a second fork liftinterface 120B. First forklift interface 120A comprises a plurality ofreceptacles 124A that are preferably dimensioned to receive the forks ofa forklift. In the embodiment of FIG. 2, each receptacle 124A comprisesa lumen 122A defined by a beam 126. Second forklift interface 120Bcomprises a plurality of receptacles 124B that are also preferablydimensioned to receive the forks of a forklift. In the embodiment ofFIG. 2, each receptacle 124B comprises a lumen 122B defined by a crossmember 128. As shown in FIG. 2, each lumen 122A has a central axis 123Aand each lumen 122B has a central axis 123B. In a preferred embodiment,the forks of a fork lift may be inserted into either end of lumens 122A,122B.

Container 100 has longitudinal axis 101 and a lateral axis 103 thatintersect at a centroid 168 of container 100. In the embodiment of FIG.2, beams 126 and cross members 128 both comprise lengths of tubinghaving a generally rectangular cross section. In FIG. 2, it may beappreciated that each forklift interface comprises a first tubepositioned on a first side of centroid 168 of container 100 and a secondtube disposed on a second side of centroid 168 of container 100. In theembodiment of FIG. 2, the first tube and the second tube of eachforklift interface are positioned substantially equidistantly fromcentroid 168 of container 100.

In FIG. 2 it may be appreciated that first forklift interface 120A and asecond fork lift interface 120B are disposed at an angle relative to oneanother. In the embodiment of FIG. 2, each cross member 128 is arrangedat about a 90 degree angle relative to each beam 126.

In FIG. 2, it may be appreciated that container 100 includes a pluralityof first mating elements 130 and second mating elements 132. In theembodiment of FIG. 2 each first mating element 130 comprises a post 134and each second mating element 136 comprises a socket 138. In someembodiments of the present invention, sockets 140 are dimensioned andlocated to accept the posts 142 of a second substantially similarcontainer.

FIG. 3 is a perspective view of an assembly including a vehicle 144 anda plurality of containers 25 that are disposed within the walls 74 ofvehicle 144. In some methods in accordance with the present invention, aplurality of containers 25 are mated with one another in an interlockingstacked configuration. In the embodiment of FIG. 3, vehicle 144comprises a semitrailer 150. It is to be appreciated that a containermay be transported using various vehicles without deviating from thespirit and scope of the present invention. Examples of vehicles whichmay be suitable in some applications include trucks, airplanes, ships,trains, and fork lifts.

FIG. 4 is a plan view of an assembly including a semitrailer 150 and aplurality of containers 25 located within a plurality of walls 74 ofsemitrailer 150.

FIG. 5 is a perspective view of a frame assembly 152 in accordance withan exemplary embodiment of the present invention. Frame assembly 152includes a frame 154 and a plurality of combs 156 that are selectivelycoupled to frame 154. Each comb 156 of frame assembly 152 comprises abase 158 and a plurality of tines 160 extending away from the base 158.Frame 154 of frame assembly 152 includes a plurality of beams 126 and aplurality of cross members 128 fixed to beams 126, for example bywelding.

First forklift interface 120A comprises a plurality of receptacles 124Athat are preferably dimensioned to receive the forks of a forklift. Inthe embodiment of FIG. 2, each receptacle 124A comprises a lumen 122Adefined by a beam 126. Second forklift interface 120B comprises aplurality of receptacles 124B that are also preferably dimensioned toreceive the forks of a forklift. In the embodiment of FIG. 2, eachreceptacle 124B comprises a lumen 122B defined by a cross member 128. Asshown in FIG. 2, each lumen 122A has a central axis 123A and each lumen122B has a central axis 123B. In a preferred embodiment, the forks of afork lift may be inserted into either end of lumens 122A, 122B.

Frame 154 has longitudinal axis 125 and a lateral axis 127 thatintersect at a centroid 168 of frame 154. In the embodiment of FIG. 5,beams 126 and cross members 128 both comprise lengths of tubing having agenerally rectangular cross section. In FIG. 5, it may be appreciatedthat each forklift interface comprises a first tube positioned on afirst side of a centroid of the container and a second tube disposed ona second side of the centroid of the container. In the embodiment ofFIG. 5, the first tube and the second tube of each forklift interfaceare positioned substantially equidistantly from the centroid of thecontainer.

In FIG. 5 it may be appreciated that first forklift interface 120A and asecond fork lift interface 120B are generally orthogonal to one another.In the embodiment of FIG. 5, each cross member 128 is arranged at abouta 90 degree angle relative to each beam 126.

FIG. 6 is an exploded perspective view of a portion of frame assembly152 of FIG. 5. In the embodiment of FIG. 6, one comb 156 is shown in adetached position. In some embodiments of the present invention, combs156 are selectively coupled to frame 154 by a coupling mechanism 174. Inthe embodiment of FIG. 6, coupling mechanism 174 comprises a plunger 176that is fixed to frame 154 and a detent 178 defined by base 158 of comb156. Detent 178 is preferably dimensioned to accept at least a portionof plunger 176. Plunger 176 may comprise, for example, a ball and aspring that is arranged to bias the ball toward detent 178.

In FIG. 6, it may be appreciated that each tine 180 includes a shaft 182and a sleeve 184 that is disposed about shaft 182. In a preferredembodiment, each sleeve 184 comprises a no-mar material that is selectedto avoid damaging, marking, or causing blemishes on a bar stockmaterial. Various no-mar materials may be used without deviating fromthe spirit and scope of the present invention. Examples of no-marmaterials which may be suitable in some applications include polymericmaterials (e.g., polyethylene and polypropylene) and elastomericmaterials (e.g., polyurethane). It is to be appreciated that a containerin accordance with the present invention may be configured to carry adesired type of bar stock by installing combs having tines that aredimensioned and spaced to receive the desired bar stock.

FIGS. 7 through 10 are cross sectional plan views of containers 100 inaccordance with the present invention. Each container 100 includes aplurality bar locating members 108 that are preferrably dimensioned andspaced for receiving desired pre-sized bars 188. In FIGS. 7 through 10,it may be appreciated that bar locating members 108 are spaced to definea plurality of channels 162 dimensioned to accept bars having a givenwidth. In the embodiments illustrated in FIGS. 7 through 10, a stack 228of bars 188 is disposed within each channel 162. Also in FIGS. 7 through10, it may be appreciated that bar locating members 108 are dimensionedto create spaces 164 between adjacent channels 162. In a preferredembodiment, each space 164 is dimensioned to receive a bar engagingmember. In this preferred embodiment, each space 164 has dimensionssuitable to allow access of a portion of a selection and retrievalsubsystem to automatically select and retrieve bars 188 from thecontainer, and deliver the bars to a desired location. The containers100 illustrated in FIGS. 7 through 10 also include a plurality ofcasters 252. Casters 252 may facilitate movement of the containers.Containers may include, for example, casters, rollers, and wheelswithout deviating from the spirit and scope of the present invention.

FIG. 11 is a perspective view of a system 192 for automaticallyselecting and retrieving desired material from an appropriate container.System 192 includes a plurality of bays 194. Each bay 194 is preferablyconfigured to receive a container. In the embodiment of FIG. 11, eachbay 194 includes a plurality of alignment pins 198.

System 192 also includes an bar engaging assembly 200 that is coupled toa motion control system 196. In the embodiment of FIG. 11, bar engagingassembly 200 includes a plurality of bar engaging members 202. In someembodiments of the present invention, two or more bar engaging members202 may be selectively urged towards one another to trap one or morebars. The force used to urge two or more bar engaging members 202towards one another may be provided by, for example, one or more aircylinders.

In the embodiment of FIG. 11, motion control system 196 includes az-axis linear actuator 204, an x-axis linear actuator 206 and aplurality of y-axis linear actuators 208. In a preferred embodiment,motion control system 196 is capable of selectively placing bar engagingassembly 200 in a desired position. Motion control system 196 maycomprise various elements without deviating from the spirit and scope ofthe present invention. For example, motion control system 196 maycomprise one or more robots, one or more linear actuators, and/or one ormore rotary actuators. Linear actuators which may be suitable in someapplications are commercially available from Lintech Corporation ofMonrovia, Calif. and Tol-o-matic Corporation of Hamel, Minn.

System 192 also includes a conveyor 220 that preferably extends throughat least a portion of system 192. In some methods in accordance with thepresent invention, conveyor 220 may be utilized to transport materialfrom system 192 to a desired location. In the embodiment of FIG. 11,conveyor 220 includes a belt 222 and a plurality of rollers 224. Barengaging assembly 200 and motion control system 196 may be used toretrieve bars and place them on belt 222 of conveyor 220.

FIG. 12 is an additional perspective view of system 192 of FIG. 11. Inthe embodiment of FIG. 12, a container 100 has been positioned in eachbay 194. For purposes of illustration, a portion of each container 100is cut-away to reveal an alignment pin 198. Thus, in FIG. 12, it may beappreciated that each container 100 includes a plurality of sockets 140that are dimensioned to receive an alignment pin 198. In some methods inaccordance with the present invention, alignment pins 198 may be used tolocate containers 100 relative to system 192.

In the embodiment of FIG. 12, each container 100 holds a plurality ofbar stock stacks 228 which are illustrated somewhat diagramatically inFIG. 12. In some embodiments, each stack 228 comprises a plurality ofbars 230 arranged one on top of the other. One bar 230 shown held by barengaging members 202 of bar engaging assembly 200. Bar engaging assembly200 and motion control system 196 may be used to select a container 100containing a plurality of desired bars, remove a desired bar, and placethe desired bar on belt 222 of conveyor 220. In FIG. 12, one bar 230 canbe seen resting on belt 222 of conveyor 220.

FIG. 13 is a cross sectional view of a container assembly 234 inaccordance with the present invention. Container assembly 234 includes acontainer 100 having a plurality of bar locating members 108. Aplurality of bars 230 are disposed between adjacent bar locating members108 to form stacks 228. In FIG. 13, a first bar engaging member 202A canbe seen disposed within a first space 164A defined by a plurality ofbars 230. A second bar engaging member 202B is disposed in a secondspace 164B defined by a plurality of bars 230. In the embodiment of FIG.13, first bar engaging member 202A and second bar engaging member 202Bhave been urged towards one another, and a bar 230 has been capturedbetween first bar engaging member 202A and second bar engaging member202B.

FIG. 14 is an additional cross sectional view of the container assembly234 of FIG. 13. In the embodiment of FIG. 14, first bar engaging member202A and second bar engaging member 202B have been moved to a newposition, for example, using motion control system 196. In FIG. 14, itmay be appreciated that a bar 230 has been lifted from container 100 byfirst bar engaging member 202A and second bar engaging member 202B.

Numerous characteristics and advantages of the invention covered by thisdocument have been set forth in the foregoing description. It will beunderstood, however, that this disclosure is, in many respects, onlyillustrative. Changes may be made in details, particularly in matters ofshape, size and ordering of steps without exceeding the scope of theinvention. The invention's scope is, of course, defined in the languagein which the appended claims are expressed.

What is claimed is:
 1. A container for handling material for theinsulating glass industry, comprising: a container frame; a plurality ofcombs fixed to the frame; each comb including a plurality of tines; thetines being spaced to define a plurality of channels dimensioned toaccept bars having a predetermined width; the tines being dimensioned tocreate spaces between adjacent channels; each space being dimensioned toreceive a bar engaging member; and the container further including afirst forklift interface and a second forklift interface.
 2. Thecontainer of claim 1, wherein each comb is fixed to the frame by acoupling mechanism comprising a plunger fixed to one of the frame andthe comb, and a detent defined by the other of the frame and the comb;the detent is dimensioned to accept at least a portion of the plunger;and the plunger comprises a ball and a spring arranged to bias the balltoward the detent.
 3. The container of claim 1, wherein each forkliftinterface comprises a first receptacle and a second receptacle.
 4. Thecontainer of claim 3, wherein each receptacle comprises a lumen definedby a tube.
 5. The container of claim 4, wherein each forklift interfacecomprises a first tube positioned on a first side of a centroid of thecontainer and a second tube disposed on a second side of the centroid ofthe container.
 6. The container of claim 5, wherein the first tube andthe second tube are positioned substantially equidistantly from thecentroid of the container.
 7. The container of claim 4, where in thelumens of the second forklift interface are disposed at an anglerelative to the lumens of the first forklift interface.
 8. The containerof claim 7, wherein the angle is about a 90 degree angle.